Jungheinrich EKX-410 (11.2003-05.2012) Electric Three-way OrderPicker Workshop Service Manual

Original Illustrated Factory Workshop Manual for Jungheinrich Electric Three-way StockPickers model EKX-410

Original factory manuals for JUNGHEINRICH Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
EKX-410 (11.2003-05.2012)

Language: English
Format: ZIP, Contained Set of PDF manuals
Contents:
1. Operating manual (11.2003-12.2009), PDF, 84 Pages
2. Operating manual (01.2010-05.2012), PDF, 205 Pages
3. Service manual, PDF, 636 Pages
   Using the truck for the first time
    A Correct use and application of the truck
    B Truck Description
       1 Application
       2 Assemblies and Operational Description
       2.1 Truck
       3 Standard Version Specifications
       3.1 Performance data
       3.2 Dimensions (as per data plate)
       3.3 EKX 410 mast version
       3.4 EKX 513 ? 515 mast version
       3.5 EN norms
       3.6 Conditions of use
       4 Identification points and data plates
       4.1 Truck data plate
       4.2 Capacity
    C Transport and Commissioning
        1 Transport
        2 Lifting by crane
        2.1 Crane points
        2.2 Lifting the battery by crane
        3 Securing the Truck for Transport.
        3.1 Basic truck transport safety
        3.2 Mast transport safety
        3.3 Mast assembled
        3.4 Transport retaining device: truck with folded mast (EKX 513 - 515)
        4 Commissioning
        4.1 Moving the truck without a battery
        4.2 Installing and removing the mast
        5 Commissioning
    D Battery Maintenance, Charging & Replacement
        1 Safety Regulations for handling acid batteries
        2 Battery types
        3 Charging the battery
        4 Battery removal and installation
        5 Battery ? checking conditionand acid level
        6 Battery discharge indicator
        E Operation
        1 Safety Regulations for the Operation of Forklift Trucks
        2 Operating and Display Equipment
        2.1 Operating and display equipment on control panel
        2.2 Display unit controls and displays
        2.3 Lower range symbols and keys
        2.4 Truck operational status symbols
        3 Starting up the truck
        4 Lift truck operation
        4.1 Safety regulations for truck operation
        4.2 Travelling, Steering, Braking
        4.3 Lifting ? Lowering ? Reaching ? Traversing outside the rack aisles
        4.4 Lifting ? Lowering ? Reaching ? Traversing inside the rack aisles
        4.5 Order picking and stacking
        4.6 Park the truck securely
        5 Troubleshooting
        5.1 Emergency stop device
        5.2 Driver?s cab / Aux. Liftemergency lowering
        5.3 Exiting the driver`s cab with the emergency abseil device
        5.4 Bypassing the chain slack safety device
        5.5 Bypassing the travel cutout (o)
        5.6 Lift cutout (o)
        5.7 Aisle end safety device (o)
        5.8 WG emergency operation
        5.9 Recovering the truck froma narrow aisle / Moving the truck without a battery
    F Maintenance of the forklift truck
        1 Operational safety and environmental protection
        2 Maintenance Safety Regulations
        3 Servicing and inspection
        4 EKX maintenance checklist
        4.1 Lubrication Schedule
        4.2 Fuels, coolants and lubricants
        5 Maintenance and Repairs
        5.1 Preparing the truck for maintenance and repairs
        5.2 Securing the driver?s position carriage
        5.3 Maintaining the lift chains
        5.4 Inspecting the lift chains
        5.5 Hydraulic oil
        5.6 Hydraulic hoses
        5.7 Checking the brake fluid (EKX 513 - 515)
        5.8 Checking electrical fuses (EKX 410)
        5.9 Checking electrical fuses (EKX 513 - 515)
        5.10 Recommissioning
        6 Decommissioning the forklift truck
        6.1 Prior to decommissioning:
        6.2 During decommissioning:
        6.3 Recommissioning
        7 Safety checks to be performed at regular intervals and following any unusual incidents
        8 Final de-commissioning, disposal
Technical Description of Components
    Notes on how to avoid accidents and material damage
    Overview of components
    A Overview
        Control panel
        Cabin
        Drive compartment
        Wire guidance
    B Drive system
        Electric motor (1 M1)
    D Brake system
        Magnetic brake
        Operational description
        Emergency recovery
    E Wheel
        Wheel bearings, load wheel
    F Steering system
        Steering system components
        Steering system electric motor (3M1)
        Sensor system 1
        Potentiometer 3U9, 8U28 and 8U29
        Distance sensor
        Angle sensor 3U9, 8U28 and 8U29
        Sensor system 2
        Steering wheel transmission table
    G Mast
        Mast sensor system
        Sensor bearing
        Power supply to sensor bearing
        Attachment
        Aux. lift sensor system
        Sideshift sensor system
        Swivel sensor system
    I Hydraulic system
        Setting and bleeding
        Overpressure setting
        Suctioning the hydraulic system
        Hydraulic motor (2M1)
        Hydraulic control block H1 assembly (drive compartment) .
        Hydraulic control block H2 assembly (cabin)
    J Electrical system
        Component Arrangement
        Operational description
        Computer
        RIO A (A2) drive compartment computer
        RIO C (A3) cabin computer
        Drive compartment and cabin computer error flashing
        codes
        I.O junction (A11)
        Power Supply - Fuses in Computer
        Control panel computer A4
        Control panel computer A4
        Input/Output
        Communication
        Displays
        Control panel computer error flashing codes
        Drive compartment travel switch distributor (U14)
        Cabin distributor (U12)
        General Description of Controller and Drive System
        Operating principles of threephase drive system
        Operational description of lift, travel and steering drive threephase controller
Test and Setting Values
    Torques
    Screw-in valve torques
    Control block 1 (main lift)
    Control block 2 (traverse/reach with aux. lift)
    Electrical Protection
    Power circuit protection
    Controller fuse rating
    Fuses in the control panel PCB
    Electrical fuse rating for RIO A (A2) computer
    EKX410 F Speed Profile
    EKX 410 1 1S Speed Profile
    Speed profile reduced
    Brake retardation
    Braking distances
    Braking in proportion to speed
    Hydraulic speeds
    Main lift
    Traverse
    Traverse/swivel cycle
    Swivel
Truck Maintenance
Judit Diagnostic Software (EKX 410/EKX 5xx(ETX-K)/EKS 310 (Kms)/EKS 314)
    General
    Installing the diagnostic software from disk
    Password/Workgroup
    Simulation or online?
    PIN number (online mode)
    Installing the operating system
    Installing the operating system via Can-Bus (control panel)
    Loading the Control Panel Computer Operating System
    Installing the operating system via components
    Loading the program in the truck
    Loading hyperterminal antenna / IO nodes
    Assembly
    Assigning hyperterminal antenna (or IO nodes)
    Status Diagnostics
    Status (ST) Parameters
    Parameter Control
    Plug`n`Play
    CanOpen Description Status (ST)
    CanOpen EKS 3xx Status (ST)
    EKS 3xx driver`s position
    EKS 3xx travel switch
    CanOpen EKX 410 status (ST)
    EKX 410 driver`s position
    EKX 41 0 travel switch
    CanOpen EKX 5xx status (ST)
    EKX 5xx driver`s position
    EKX 5xx travel switch
    CanOpen Status Info Status (ST)
    PDO (1)
    SDO (2)
    PRU (3)
    MID (module ID) (EKS 3xx)
    MID (module ID) (EKX 410)
    MID (module ID) (EKX 5xx)
    EKS 3xx
    EKS 3xx - hT1 / hT2 (5)
    EKS 3xx - hR1 / hR2 (6)
    EKX 410
    EKX 410 - hT1 / hT2 (5)
    EKX 410 - hR1 / hR2 (6)
    EKX 5xx
    EKX 5xx - hT1 / hT2 (5)
    EKX 5xx - hR1 / hR2 (6)
    Truck Status
    Emergency Stop Circuit (EKS 3xx) Status (ST)
    Emergency Stop Circuit (EKS 3xx) Figure Description
    Emergency Stop Circuit (EKS 3xx) Figure Description
    Emergency Stop Circuit (EKX 410, EKX 5xx) Status (ST)
    Emergency Stop Circuit (EKX 410, EKX 5xx) Figure Descripti
    30
    Emergency Stop Circuit (EKX 410, EKX 5xx) Figure Descripti
    31
    Status (ST) PSS (Personal Safety System)
    From Truck to PSS
    From PSS to Truck
    Scanner release (1) height
    Test Functions
    TST_Emergency Stop Reactions
    Emergency Stop Reaction Test
    Wire break safety device test
    Steering and Travel Test
    TST Emergency Stop Displays
    Displays
    Administering Parameter Lists
    Storing parameters
    Saving to Disk
    Saving to Computer
    Viewing / Editing Parameter List
    Loading a Parameter List
    Warehouse zone Ground System through
    Transponder 38
    Warehouse zone parameter setting
    Requirement
    Transponder Figure Description
    Transponder data
    Warehouse zone commissioning
    Transponder programming
    Programming and Assigning Warehouse Zones
    1. Programming and Assigning Warehouse Zones
    2. Programming and Assigning Warehouse Zones
    3. Programming and Assigning Warehouse Zones
    4. Programming and Assigning Warehouse Zones
    5. Programming and Assigning Warehouse Zones
        Assigning alternately in load direction (LD) and drive directioon (DD) on entry
    6. Special Programming
        Example: Entry in load direction with sufficient clearance height in a zone
    7. Special Programming
        Example: Entry in load direction with sufficient clearance height in a zone
    8. Special procedure
        Example: Entry in load direction with sufficient clearance height in a zone
    9. Special Programming
        Example: Entry in load direction with sufficient clearance height in a zone
    10. Special Programming
        Example: Entry in load direction with sufficient clearance height in a zone
    11. Special Programming
        Example: Entry in load direction with sufficient clearance height in a zone
    12. Special Programming
    Example: Entry in load direction with sufficient clearance height in a zone
    Error messages
Service Instructions
Ground Systems and Warehouse Zones
    A Ground Systems
        Functional Description F1
        Functional Description F2
        Functional Description F3
        Functional Description F4
        Functional Description F5
        Functional Description F6
        Functional Description F7
        Functional Description F8
        Functional Description F9
        Functional Description F18
        Functional Description F61
        Functional Description F101
        Functional Description F200
        Functional Description F201
        Functional Description F202
        Functional Description F203
        Functional Description F204
        Functional Description F205
    B Warehouse Areas / Track Assignment
        Tracks and Track Values
        Warehouse zone 0
        Warehouse zone 1
        Warehouse zone 2
        Warehouse zone 3
        Warehouse zone 4
        Warehouse zone 5
        Warehouse zone 6
        Warehouse zone 7
        Warehouse zone 8
    C Warehouse Zone I Area Recognition via
        Transponders 8.31
        Requirement
        Function
        Creating a diagram
        Transponder
        Routing
        Transponder and Entry Direction
        Entry only in load direction (LD)
        Entry only in drive direction (DD)
        Entry in LD and DD
Electrical Diagrams
Hydraulic diagrams
Service Manual Items
    Tilt Safety Device / Support Pillar
    Settings
    Drive motor sensor bearing
    Disassembly/Assembly
    AC-3 Power Control
    Magnetic Brake Setting
    Vulkolan Wheel Wear Limits
    Load chains
    Cleaning / Inspection / Lubrication
    Pump Motor Sensor Bearing
    Disassembly/Assembly
    Notes on how to avoid accidents and material damage during maintenance, test and repair work on industrial trucks with electronic components
    Wire guidance line driver with emergency power supply (Dataschalt)
    Wire guidance line driver with emergency power supply (INRO)
    Notes on how to avoid malfunctions and material damage when cleaning an industrial truck
    Colour Coding Key
    Brake delay (table) + Brake system principle overview
    Brake Record
    Magnetic Brake
    Connector Layout (with AC 3 Power Control Combination Controller)
    Gearbox Oil Change
    Drive Wheel Disassembly/Assembly
    Rail Guidance Wheel Disassembly/Assembly
    Nord-Lock Lockwashers
    RG 16-E Rescue Belt
    Description / Maintenance / Testing
    Abseil Device AG 10 / AG 1 0 S
    Description / Maintenance / Testing
    Adjusting the Tension Spring Path on the Mast Cable
    Marker Ring Adjustment on Dipstick
    Bleeding the Hydraulic Cylinders
    Adjusting the Clearance Height
    Mast Tilt Measurement and Adjustment
    Conversion of Traverse
    Potentiometer (8U29) to Traverse Angle Sensor (8U29)
    Conversion of Traverse/Rotate
    Potentiometer (8U28) to a Traverse/ Rotate Angle Sensor (8U28)
    Commissioning Record
    User instruction guidelines
    Disassembly/Assembly of the Sensor Bearing (3B17) on the Steer Motor (3M1)
    Steering Actual Value Transmitter (3U9)
    Conversion of Steer Potentiometer (3U9) to Steer Angle Sensor (3U9)
    Description of steering setpoint device (3U9), rotate/traverse setpoint device (8U28) and traverse setpoint device (8U29)
    Electronic lock
    Wire Guidance Commissioning
    Wire guidance - test distance measurement and safety cutout (cutout limits)